NXP TEA1832DB1253 User guide

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UM10862
TEA1832DB1253 45 W demo board
Rev. 1.1 — 18 June 2015 User manual
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Keywords TEA1832DB1253, TEA1832TS, TEA1832LTS, notebook adapter
Abstract This user manual provides the specification, schematics and PCB layout
of the TEA1832DB1253 45 W (90 W peak) demo board. See the data
sheet and application note for more information on the TEA1832TS/LTS
IC.
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User manual Rev. 1.1 — 18 June 2015 2 of 27
Contact information
For more information, please visit: http://www.nxp.com
For sales office addresses, please send an email to: [email protected]
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TEA1832DB1253 45 W demo board
Revision history
Rev Date Description
v.1.1 20150618 updated issue
Modifications:
Figure 15 “TEA1832DB1253 schematic has been updated.
v.1 20150513 first issue
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1. Introduction
The TEA1832DB1253 demo board demonstrates the capabilities of the low-cost 6-pin
TEA1832TS/LTS Switched-Mode Power Supply (SMPS) controller. This user manual
describes the specification, the schematics, and the PCB layout of the TEA1832DB1253
45 W demo board. See the data sheet and application note for more information on the
TEA1832TS/LTS IC.
Remark: Unless otherwise specified, all values are typical values.
1.1 Features
Low no-load power (< 55 mW at 230 V (AC), output still in regulation)
200 % peak power
Universal mains supply operation
Low ripple and noise
Small form factor
Low-cost design
Efficiency DoE 2016 and COC 2014 compliant
EMI CISPR22 compliant
Brownin and brownout protection
Output OverVoltage Protection (OVP)
OverTemperature Protection (OTP)
OverPower Protection with high/low compensation
OverCurrent Protection (OCP)
Output Short Circuit Protection (OSCP)
WARNING
Lethal voltage and fire ignition hazard
The non-insulated high voltages that are present when operating this product, constitute a
risk of electric shock, personal injury, death and/or ignition of fire.
This product is intended for evaluation purposes only. It shall be operated in a designated test
area by personnel qualified according to local requirements and labor laws to work with
non-insulated mains voltages and high-voltage circuits. This product shall never be operated
unattended.
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2. Safety warning
The TEA1832DB1253 demo board input is connected to the mains voltage. Avoid
touching the board while it is connected to the mains voltage and when it is in operation.
An isolated housing is obligatory when used in uncontrolled, non-laboratory environments.
Galvanic isolation from the mains phase using a fixed or variable transformer is always
recommended. Figure 1
shows the symbols on how to recognize these devices.
a. Isolated b. Not isolated
Fig 1. Isolation symbols
019aab173
019aab174
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3. Power supply specification
Table 1 lists the specification of the TEA1832DB1253 demo board.
Table 1. TEA1832DB1253 specifications
Symbol Parameter Value
V
i
input voltage 90 V to 264 V
f
i
input frequency 47 Hz to 64 Hz
P
i
input power < 55 mW; no-load
V
o
output voltage 19.5 V
V
o(ripple)(p-p)
ripple output voltage < 150 mV (pp); full load;
20 MHz bandwidth;
10 F capacitor at end of cable
P
o(nom)
nominal output power 45 W
P
o(peak)
peak output power > 90 W; 2 ms peak load during 50 %
continuous load; 100 V (AC); 50 Hz;
measured at end of cable
V
o(peak)
output voltage during peak load > 18 V; 2 ms 200 % peak load during
50 % continuous load; 100 V (AC);
50 Hz; measured at end of cable
t
holdup
hold-up time > 5 ms; 115 V (AC); 60 Hz; full load
t
startup
start-up time < 2 s; 115 V (AC); 60 Hz
<3s; 90V(AC); 60Hz
efficiency > 89 %; average; measured at end of
cable
> 83 %; at 10 % load
> 60 %; at 0.6 % load
(= at 270 mW load)
V
line(reg)
line voltage regulation < 1 %; 90 V (AC) to 264 V (AC);
measured at the PCB
V
load(reg)
load voltage regulation < 1 %; no-load to full load (2.3 A);
measured at the PCB
EMI conducted EMI > 5 dB margin; according to CISPR22
P
o(opp)
OPP trigger level 50 W to 60 W; over full input voltage
range
V
O(ovp)
overvoltage protection output
voltage
< 24 V (DC)
V
bi
brownin voltage 75 V (AC) to 85 V (AC)
V
bo
brownout voltage 65 V (AC) to 75 V (AC); over full load
range
P
i(shorted_output)
average input power at
continuously shorted output
<1W; 264V(AC)
T
otp
overtemperature protection
temperature
105 C; ±5 C; diode and NTC same
temperature
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4. Board photographs
Fig 2. TEA1832DB1253 demo board photograph - Top view
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5. Performance
Performance figures are based on PCB design:
Schematic version: v.3 (see Figure 15)
5.1 Efficiency
Efficiency measurements are taken using an automated test program containing a
temperature stability detection algorithm. The output voltage and output current are
measured using a 4-wire current sense configuration directly at the PCB connector.
Measurements are performed for:
115V/60Hz
230V/50Hz
After subtracting 0.975 % from the 4-point average efficiency result for cable losses, the
board complies with all efficiency standards listed below.
Table 2. High load efficiency
Measured directly at the PCB; see Section 5.1.1 for more information about how to calculate efficiency at end of cable.
Condition Efficiency at specified load
10 %;
4.5 W
25 %;
11.25 W
50 %;
22.5 W
75 %;
33.75 W
100 %;
45 W
4-point
average
115 V (AC)/60 Hz 88.74 % 90.24 % 90.70 % 90.01 % 89.23 % 90.05 %
230 V (AC)/50 Hz 87.52 % 88.64 % 90.33 % 90.65 % 90.46 % 90.02 %
Table 3. Low load efficiency
Measured directly at the PCB
Condition Efficiency at specified load
0.1 W;
0.22 %
0.2 W;
0.44 %
0.5 W;
1.11 %
1W;
2.22 %
2W;
4.44 %
115 V (AC)/60 Hz 69.36 % 78.35 % 85.65 % 87.77 % 88.89 %
230 V (AC)/50 Hz 56.52 % 69.12 % 80.34 % 84.02 % 86.02 %
Table 4. Efficiency standards
Standard 10 % load 4-point average
(25 %; 50 %; 75 %; 100 %)
COC 2014 78.43 % 88.43 %
COC 2016 78.85 % 88.85 %
DoE 2008 - 84.26 %
DoE 2016 - 87.73 %
Energy Star 2.0 - 86.03 %
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5.1.1 Cable loss
At full load, the cable loss reduces the efficiency by:
(1)
The resistance of a 1.8 m 20 AWG cable is approximately 120 m which reduces the
efficiency at full load by .
For the 4-point average, the result of the formula above must be multiplied by 0.625
1
so for the 4-point average the efficiency is reduced by 0.97 %.
At a 10 % load, the influence of the cable can already be neglected.
5.1.2 Output diode
Replacing the 20 A Schottky diode (D5 in Figure 15) by a 40 A Schottky diode, for
example, the Vishay V40100C can improve the efficiency about 0.5 %.
5.2 No-load power consumption
Measurement details:
Power meter Yokogawa WT210
Integrated over 36 s
AC source Agilent 6812B
No probes or ground clips connected to board
1. At low output current, the cable losses rapidly decrease: reducing the output current by a factor 2 decreases the cable losses by a
factor 4.
Table 5. Cable loss for different types of cable
Cable thickness
(AWG)
Cable length
(m)
Resistance at 20 C
(m)
Efficiency loss
(4-point average)
(%)
16 1.2 32 0.26
1.8 47 0.39
18 1.2 50 0.41
1.8 75 0.71
20 1.2 80 0.65
1.8 120 0.97

P
cable
P
nom
--------------------
100 %
I
nom
2
R
cable
P
nom
--------------------------------
100 %
2.3 A
2
R
cable
0.9 45 W
----------------------------------------
100 %== =
R
cable
13 %=
13 % 120 m 1.56 %=
Table 6. No-load power measurements
Input condition No-load power
90 V (AC)/60 Hz 24.8 mW
115V(AC)/60Hz 27.4mW
230V(AC)/50Hz 48.8mW
264V(AC)/50Hz 58.7mW
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5.3 Load regulation
The output voltage as a function of load current is measured directly at the PCB and at the
end of the cable at 115 V (AC)/60 Hz.
Table 7. No-load power requirements
Standard No-load power
COC 2014 150 mW
COC 2016 75 mW
DoE 2008 300 mW
DoE 2016 100 mW
Energy Star 2.0 300 mW
(1) Measured at the PCB.
(2) Measured at the end of the cable.
Fig 3. Output voltage as a function of output current
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5.4 Line regulation
The output voltage as a function of mains input voltage is measured directly at the PCB at
full load (2.3 A) and at 60 Hz.
5.5 High/low line compensation
The maximum continuous output power is measured at the PCB as function of the mains
voltage at 60 Hz.
If necessary, the OPP level can be increased by decreasing resistors R11 and R12 to
0.47 and increasing capacitor C1 to 82 F. In that case resistor R13 must be increased
to limit the output power at high input voltages. See the TEA1832 application note (Ref. 3
)
for more information about how to tune R13 and R27.
Fig 4. Output voltage as a function of mains voltage
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Fig 5. Overpower protection threshold as a function of mains voltage
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5.6 Peak power
5.6.1 Example 1
Load: 200 % peak (4.6 A) for 2 ms when continuously running at 50 % load (10 ms)
Input voltage: 100 V (AC); 47 Hz
Output voltage: remains above 18 V (18.44 V)
The output voltage was measured at end of the cable.
Green: Output voltage
Blue: Output voltage (bottom of screen is 15 V)
Fig 6. 200 % peak load for 2 ms when continuously running at 50 % load (accumulated
over 30 s)
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5.6.2 Example 2
Load: 200 % peak (4.6 A) for 1 ms when continuously running at 100 % load (10 ms)
Input voltage: 90 V (AC); 47 Hz
Output voltage: remains above 17 V (17.59 V)
The output voltage was measured at end of the cable.
For an even higher or longer peak load, decrease current sense resistor and increase bulk
capacitor (also increases the maximum continuous output power) or increase the output
capacitor.
5.7 VCC voltage
The VCC voltage is measured at different input and loading conditions. It is within a safe
margin of the UVLO level and the OVP level.
Green: Output voltage (bottom of screen is 15 V)
Fig 7. 200 % peak load for 1 ms when continuously running at 100 % load (accumulated
over 30 s)
Table 8. VCC voltage
The two voltages are the minimum and the maximum value of the VCC ripple.
Condition 90 V (AC)/60 Hz 264V(AC)/50Hz
no-load 15.55 V to 17.25 V 15.05 V to 17.40 V
90 W peak load 24.50 V to 24.95 V 24.55 V to 24.75 V
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5.8 Brownout and start-up level
Brownout and start-up level were measured at no-load and at full load in 0.5 V steps.
5.9 OverVoltage Protection (OVP)
Applying a short circuit across the LED of the photocoupler (U2) creates an output
overvoltage condition. The output voltage is measured directly at the PCB.
The OVP trigger level can be adjusted by changing resistor R27.
Table 9. Brownout and start-up level
Condition Start-up voltage Brownout voltage
no-load 83.5 V (AC) 73.5 V (AC)
full load (2.3 A) 83.5 V (AC) 75.0 V (AC)
Table 10. Maximum output voltage
Condition 115 V (AC)/60 Hz 230V(AC)/50Hz
no-load 22.75 V 22.75 V
full load (2.3 A) 22.75 V 22.75 V
(1) Orange: VCC
(2) Blue: V
o
Fig 8. Overvoltage protection (230 V (AC)/50 Hz; full load)
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5.10 Start-up time
The start-up time was measured without connecting any voltage probes. All capacitors
were fully discharged before starting up.
5.11 Start-up sequence
Figure 9 and Figure 10 show waveforms of some essential voltages. These waveforms
were captured during start-up at full load.
Table 11. Start-up time measured at three input voltages
Input voltage Start-up time
90 V (AC)/60 Hz 2.35 s
115V(AC)/60Hz 1.56s
230V(AC)/50Hz 0.64s
(1) Orange: VCC
(2) Magenta: CTRL
(3) Green: DRIVER
(4) Blue: V
o
Fig 9. Start-up waveforms at 115 V AC)/60 Hz
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5.12 Hold-up time
The hold-up time at 115 V (AC)/50 Hz is 9.0 ms.
(1) Orange: VCC
(2) Magenta: CTRL
(3) Green: DRIVER
(4) Blue: V
o
Fig 10. Start-up waveforms at 230 V (AC)/50 Hz
(1) Magenta: Bulk capacitor voltage
(2) Blue: V
o
Fig 11. Hold-up time at 115 V (AC)/50 Hz
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The hold-up time was measured from the last valley of the bulk capacitor ripple (worst
case moment for mains interruption) until the output voltage starts to drop (drops to below
18.5 V).
5.13 Average input power at continuously shorted output
Measurement details:
Output was shorted at the end of the cable
Power meter Yokogawa WT210
Current range 5 A
Integration time 36 s
5.14 Output ripple and noise
Measured at full load with a 10 F/50 V capacitor (United Chemi Con; KY series) at end of
the cable. The oscilloscope bandwidth was limited to 20 MHz.
Table 12. Input power at continuously shorted output
Condition Input power
90 V (AC)/60 Hz 168 mW
115V(AC)/60Hz 192mW
230V(AC)/50Hz 618mW
264V(AC)/50Hz 760mW
Table 13. Output ripple and noise
Condition V
o(ripple)(p-p)
90 V (AC) 81 mV (pp)
264 V (AC) 81 mV (pp)
Fig 12. Output voltage ripple and noise at 264 V (AC)/50 Hz
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5.15 OverTemperature Protection (OTP)
The external OTP triggers at 105 C, measured in an oven at 115 V (AC)/60 Hz at no-load
operation.
5.16 EMI performance
Conducted EMI measurement details:
Full load (passive load 8.33 at end of cable)
Supply voltage 115 V (AC) and 230 V (AC)
Frequency range 150 kHz to 30 MHz
Test receiver Rohde & Schwarz ESPI3
Line impedance stabilization network Rohde & Schwarz ENV216
Remark: In Figure 13
and Figure 14, the blue line is the peak measurement result and the
black line is the average measurement result.
a. Line b. Neutral
Fig 13. Conducted EMI performance at 115 V (AC)/60 Hz
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a. Line b. Neutral
Fig 14. Conducted EMI performance at 230 V (AC)/50 Hz
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6. Schematic
Fig 15. TEA1832DB1253 schematic
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UM10862 All information provided in this document is subject to legal disclaimers. © NXP Semiconductors N.V. 2015. All rights reserved.
User manual Rev. 1.1 — 18 June 2015 20 of 27
NXP Semiconductors
UM10862
TEA1832DB1253 45 W demo board
7. Bill Of Materials (BOM)
Table 14. TEA1832DB1253 bill of materials
Reference Description and values Part number Manufacturer
BC1 not mounted; ferrite core; on pin CY1 74270073 Würth Elektronik
BD1 bridge diode; 2 A; 600 V KBP206G Diodes Inc.
C1 capacitor; 68 F; 400 V; 105 C 400BXW68MEFC18X20 Rubycon
C2 capacitor; 3.3 nF; 1 kV; X7R; 1206 - -
C3 capacitor; 2.2 nF; 630 V; X7R; 1206 - -
C4 capacitor; not mounted; 100 pF; 1 kV;
X7R; 1206
--
C7 capacitor; 100 nF; 50 V; X7R; 0603 - -
C9; C10; C15 capacitor; 1 nF; 50 V; X7R; 0603 - -
C11 capacitor; 2.2 F; 50 V; 105 C;
5mm 11 mm
50YXJ2R2MTA5X11 Rubycon
C13 capacitor; 680 F; 25 V; 105 C;
10 mm 20 mm
EKZE250ELL681MJ20S United Chemi Con
C16 capacitor; 10 nF; 50 V; X7R; 0603 - -
C18 capacitor; 220 pF; 100 V; NPO; 0805 - -
C19 capacitor; 100 nF; 50 V; X7R; 1206 - -
C20 capacitor; not mounted; 220 pF; 50 V;
X7R; 0603
--
CX1 capacitor; 220 nF; 275 V (AC); X2 - HJC
CY1 capacitor; 1.5 nF; 250 V (AC); Y1 DE1E3KX152MA5BA01 Murata
D1 diode; 1 kV; 2 A SA2M-E3/61T Vishay
D2 diode; 100 V; 250 mA BAS316 NXP Semiconductors
D3; D8 diode; 200 V; 200 mA BAS21H NXP Semiconductors
D5 diode; Schottky; 100 V; 2 10 A; TO220 NXPS20H100CX NXP Semiconductors
D6 diode; 85 V; 200 mA BAS416 NXP Semiconductors
D7 diode; dual; common cathode; 85 V;
100 mA
BAV70W NXP Semiconductors
D9; D10 diode; Zener; 75 V; 250 mW; SOD323F BZX84J-B75 NXP Semiconductors
F1 fuse; slow blow; 3.15 A; 250 V (AC) MST 3.15A 250V Multicomp
HS1 heat sink for Q1 - -
HS2 heat sink for D5 - -
L1 inductor; 3.3 H; 1.2 A LQM2HPN3R3MG0L Murata
LF1 choke; common mode; not mounted;
shorted by wire bridge;
diameter = 0.8 mm; pitch 5.08 mm
--
LF2 choke; common mode; 2 6.8 mH B82721K2122N20 EPCOS
M1; M2 screw; M3 8; for mounting Q1 and D5 - -
M3; M4 spring washer; M3;
for mounting Q1 and D5
--
M5; M6 nut; M3; for mounting Q1 and D5 - -
Q1 MOSFET; N-channel; 600 V; 10 A TK10A60D Toshiba
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NXP TEA1832DB1253 User guide

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